STARTER INSPECTION [MZR-CD 2.2]

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On-vehicle Inspection

1.  Verify that the battery is fully charged.

2.  The starter is normal if it rotates smoothly and without any noise when the engine is cranked.

•  If the starter does not operate, inspect the following:
―  Remove the starter, and inspect the starter unit.
―  Inspect the related wiring harnesses and the ignition switch, and starter interlock switch.


No-load test

1.  Verify that the battery is fully charged.

2.  Connect the starter, battery, and a tester as shown in the figure.

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3.  Operate the starter and verify that it rotates smoothly.

•  If the starter does not rotate smoothly, inspect the starter unit.

4.  Measure the voltage and current while the starter is operating.

•  If not within specification, replace the starter.
Starter no-load test voltage
11 V
Starter no-load test current
120 A or less


Magnetic Switch Operation Inspection


Pull-out test

Note
•  Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state. This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does not indicate an abnormality.

1.  Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S and the starter body is grounded.

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•  If the starter motor pinion is not extended, repair or replace the starter.


Return test

1.  Disconnect the motor wire from terminal M.

2.  Connect battery positive voltage to terminal M and ground the starter body.

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3.  Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released.

•  If it does not return, repair or replace the starter.


Pinion Gap Inspection

1.  Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded.

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Caution
•  Applying power for more than 10 s can damage the starter. Do not apply power for more than 10 s.

2.  Measure the pinion gap while the drive pinion is extended.

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•  If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch).
Starter pinion gap
0 mm {0 in}


Starter Inner Parts Inspection


Armature

1.  Verify that there is no continuity between the commutator and the core at each segment using a tester.

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•  If there is continuity, replace the armature.

2.  Verify that there is no continuity between the commutator and the shaft using a tester.

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•  If there is continuity, replace the armature.

3.  Place the armature on V-blocks, and measure the runout using a dial indicator.

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•  If not within specification, replace the armature.
Starter armature runout
0.1 mm {0.004 in} max.

4.  Measure the commutator diameter.

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•  If not within the minimum specification, replace the armature.
Starter commutator diameter
Standard: 29.4 mm {1.16 in}
Minimum: 28.8 mm {1.13 in}

5.  Measure the segment groove depth of the commutator.

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•  If not within the minimum specification, undercut the grooves to the standard depth.
Segment groove depth of starter commutator
Standard: 0.5 mm {0.02 in}
Minimum: 0.2 mm {0.008 in}


Magnetic switch

1.  Inspect for continuity between terminals S and M using a tester.

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•  If there is no continuity, replace the magnetic switch.

2.  Inspect for continuity between terminal S and the body using a tester.

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•  If there is no continuity, replace the magnetic switch.

3.  Verify that there is no continuity between terminals M and B using a tester.

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•  If there is continuity, replace the magnetic switch.


Brush and brush holder

1.  Verify that there is no continuity between each insulated brush and plate using a tester.

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•  If there is continuity, replace the brush holder.

2.  Measure the brush length.

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•  If any brush is worn almost to or beyond the minimum specification, replace all of the brushes.
Starter brush length
Standard: 17.6 mm {0.693 in}
Minimum: 10.0 mm {0.394 in}

3.  Measure the brush spring force using a spring balance.

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•  If not within the minimum specification, replace the brush and brush holder component.
Starter brush spring force
Standard: 23.4—31.6 N {2.39—3.22 kgf, 5.27—7.10 lbf}
Minimum: 10.0 N {1.20 kgf, 2.25 lbf}